TSI Date Group No. Supp. Page

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Volvo Trucks North America, Inc. Greensboro, NC USA This TSI Service Bulletin and others in Groups 21 and 33 replace TSI Service Manual 210 600, Basic Engine, D12, D12A, D12B, D12C (8.

1 Volvo Trucks North America, Inc. Greensboro, NC USA This TSI Service Bulletin and others in Groups 21 and 33 replace TSI Service Manual , Basic Engine, D12, D12A, D12B, D12C (8.2000), publication no. PV776 TSP Timing Gears Replacement TSI Date Group No. Supp. Page (11) Timing Gears Replacement D12, D12A, D12B Fig. 1: VOLVO D12B Engine W This information covers procedures for replacement of the timing gears on VOLVO D12, D12A, and D12B engines. Contents Special Tools page 2 Timing Gears, Replacement (All) page 4 PV776-TSP USA10309

Page 2 Special Tools Tools The following special

The tools can be ordered from Volvo; please use

9992584 Hollow Drift 9992658 Crankshaft Drive

capacity 9996160 Pins, used with Yoke 9996358

Gear Yoke 9996401 Puller Arms 9996413 Adapter

2 Page 2 Special Tools Tools The following special tools are used to replace or repair components. The tools can be ordered from Volvo; please use the specified part number when ordering Hollow Drift Crankshaft Drive Gear Puller Hydraulic Cylinder, 18-ton capacity Pins, used with Yoke Foot Pump Spindle Timing Gear Yoke Puller Arms Adapter Hydraulic Cylinder, 10-ton capacity Adapter Hollow Drift

3 Volvo Trucks North America, Inc. Date Group No. Page TSI (11) Flywheel Blocking Tool Flywheel Turning Tool Polygon Hub Puller Puller Drift Gear Wheel Puller Counterhold Rocker Dial Indicator Magnetic Stand

4 Page 4 Service Procedures Timing Gears, Replacement (All) (Oil pan and timing gear cover removed) WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids. CAUTION Never turn the crankshaft or camshaft when the timing gears have been removed. Otherwise, the pistons can come into contact with the valves resulting in damage to engine components. Special tools: , , , , , , , , , , , , , , , , , , , , , Removal of Drive and Idler Gears 1 Fig. 3: Cranking tool installed T T Fig. 2: Timing gear arrangement Remove the inspection cover from beneath the flywheel housing and install cranking tool Description (no. of teeth): 1 Crankshaft Drive Gear (36) 2 Idler Gear, 36 mm (87) 3 Coolant Pump Drive Gear (24) 4 Air Compressor Drive Gear (27) 5 Camshaft (72) 6 Adjustable Idler Gear (58) 7 Upper Idler Gear (60) 8 Lower Idler Gear (58) 9 Power Steering Pump Drive Gear (22) 10 Drive Gear Arrangement (Accessory Drive Pulley and Fuel Feed Pump) (26) 11 Power Take Off (PTO) Idler Gear, 28 mm (87) 12 Power Take Off (PTO) Drive Gear for Hydraulic Pump (37) 13 Oil Pump Drive Gear (24) 14 Oil Pump Idler Gear (57)

Volvo Trucks North America, Inc. Date Group No. Page TSI 11.2001 215 004 5(11) 2 4 Fig. 4: Aligning camshaft W2000936 Fig.

5 Volvo Trucks North America, Inc. Date Group No. Page TSI (11) 2 4 Fig. 4: Aligning camshaft W Fig. 6: Vibration dampener T Rotate the flywheel until number 1 piston is at TDC and the camshaft marking is opposite the marking on the cap. 3 Fig. 7: Removing polygon hub T Fig. 5: Blocking tool installed Remove cranking tool and install blocking tool T Remove the vibration dampener. Remove the crankshaft bolt together with the washer. Secure the puller on the polygon hub. Fit adapter on hydraulic cylinder Screw the hydraulic cylinder to the puller and pull off the polygon hub using foot pump Remove idler gears (see 2, 6 and 11, Fig. 2: Timing gear arrangement, page 4) from the timing gear plate Remove the washers from the upper and lower idler gear (see 7 and 8, Fig. 2: Timing gear arrangement, page 4). 7 Remove the socket head bolts and remove upper and lower idler gears (see 7 and 8, Fig. 2: Timing gear arrangement, page 4). Use two screwdrivers to assist in removal.

6 Page Fig. 8: Cam sensor wheel T T Fig. 10: Removing the crankshaft drive gear Remove the cam sensor wheel from the camshaft drive gear. 9 Using cylinder , pins , puller arms , and yoke connected to pump , remove the crankshaft drive gear (see 1, Fig. 2: Timing gear arrangement, page 4) Remove the retaining bolts in the oil pump idler gear and remove the idler gear from the oil pump (see 14, Fig. 2: Timing gear arrangement, page 4). 12 T Fig. 9: Installing counterhold tool Attach the camshaft holding tool to the rear camshaft support. Remove the camshaft gear retaining bolt and remove the camshaft drive gear (see 5, Fig. 2: Timing gear arrangement, page 4) T Fig. 11: Removing the oil pump drive gear Install an M12x20 bolt in the shaft for the oil pump drive gear (see 13, Fig. 2: Timing gear arrangement, page 4). Remove the gear, using tool and drift

7 Volvo Trucks North America, Inc. Date Group No. Page TSI (11) 13 Remove the air compressor drive gear (see 4, Fig. 2: Timing gear arrangement, page 4). Installation of Drive and Idler Gears Remove the power steering pump drive gear (see 9, Fig. 2: Timing gear arrangement, page 4). 15 Install puller onto the coolant pump drive gear (see 3, Fig. 2: Timing gear arrangement, page 4). Place a plug on the shaft as a support and pull off the gear T T Fig. 12: Installation of crankshaft drive gear Install adapter and spindle on the crankshaft. Install the new crankshaft drive gear (see 1, Fig. 2: Timing gear arrangement, page 4) on the spindle Install drifts and and hydraulic cylinder Install the nut and carefully press on the drive gear, using pump Note: Make sure that the key remains in position in the keyway. Remove the tools.

Page 8 17 21 T2007078 Idler gears Lubricate the oil pump idler gear (see 14, Fig. 2: Timing gear arrangement, page 4) bearing and install. Torquetighten bolts to 24 ± 4 Nm (18 ± 3 ft-lb).

8 Page T Idler gears Lubricate the oil pump idler gear (see 14, Fig. 2: Timing gear arrangement, page 4) bearing and install. Torquetighten bolts to 24 ± 4 Nm (18 ± 3 ft-lb). T ± 4 Nm (18 ± 3 ft-lb) T Fig. 13: Installation of the oil pump drive gear Heat the oil pump drive gear (see 13, Fig. 2: Timing gear arrangement, page 4) to approximately 180 C (360 F) and tap it onto the lube oil pump. 18 Install the air compressor drive gear (see 4, Fig. 2: Timing gear arrangement, page 4). 19 Install the power steering pump drive gear (see 9, Fig. 2: Timing gear arrangement, page 4). 20 Apply assembly paste to the coolant pump shaft. Install the spindle into the shaft. Place the coolant pump drive gear (see 3, Fig. 2: Timing gear arrangement, page 4) onto the spindle and press the gear on with the help of the hydraulic cylinder. 22 Lubricate the bearings for idler gears (see 2 and 11, Fig. 2: Timing gear arrangement, page 4). Place them into position and torque-tighten bolts to 15 ± 3 Nm (11 ± 2 ft-lb). Turn an additional 120 ± 5. Note: New bolts must be used each time the idler gear is loosened or removed; these bolts are designed for single use only and cannot be torqued a second time. 23 Install upper and lower idler gears (see 7 and 8, Fig. 2: Timing gear arrangement, page 4). Torque-tighten the socket head bolts to 15 ± 3 Nm (11 ± 2 ft-lb). Turn an additional 120 ± Install the washers for the idler gears and torque-tighten to 10 ± 2 Nm (7 ± 1 ft-lb). Turn an additional 60 ± 3. Note: New bolts must be used each time the idler gear is loosened or removed; these bolts are designed for single use only and cannot be torqued a second time. 15 ± 3 Nm (11 ± 2 ft-lb) 120 ± 5 15 ± 3 Nm (11 ± 2 ft-lb) 120 ±5 10 ± 2 Nm (7 ± 1 ft-lb) 60 ± 3

9 Volvo Trucks North America, Inc. Date Group No. Page TSI (11) Fig. 14: Installing polygon hub Apply assembly paste to the crankshaft. Place the polygon hub, tool and hydraulic cylinder on Install the nut onto the spindle and use tool to press on the polygon hub. T T Fig. 16: Torque-tightening the camshaft drive gear bolt 26 T Fig. 17: Installing the camshaft drive gear Install the camshaft drive gear. Use tool as a support. Torquetighten to 645 ± 25 Nm (475 ± 18 ft-lb). 645 ± 25 Nm (475 ± 18 ft-lb) T Fig. 15: Torque-tightening the crankshaft drive gear bolt Remove the tools. Install the bolt and washer and torque-tighten to 645 ± 25 Nm (475 ± 18 ft-lb). 645 ± 25 Nm (475 ± 18 ft-lb) 27 Remove blocking tool from the flywheel housing and install flywheel turning tool

10 Page Fig. 18: Aligning the camshaft W Make sure the flywheel is at 0 and that the camshaft is at TDC (see marking). W Fig. 20: Torque-tightening sequence for adjustable idler gear 30 Install the adjustable idler gear (see 6, Fig. 2: Timing gear arrangement, page 4). Note: Hand-tighten the bolts until they bottom against the bearing shield (these bolts will be individually replaced in a later step). 31 Use a two-step process to torquetighten the idler gear bolts: Tighten to 15 ± 3 Nm (11 ± 2 ft-lb). Turn bolts an additional 120 ± 5. Note: The bolts for the adjustable idler gear are NOT reusable. If they are loosened or removed, they MUST be replaced with new bolts ± 3 Nm (11 ± 2 ft-lb) 120 ± 5 Fig. 19: Idler gear adjustment Adjust the idler gear using two feeler gauges. The correct backlash is mm ( in.). By using feeler gauges, an equal amount of backlash between cam gear and the nonadjustable upper idler gear can be obtained. T T Fig. 21: Checking the backlash After adjustment, check the backlash with rocker dial indicator mounted on magnetic base Note: It is important that backlash is the same for both gear wheels which mesh with the adjustable idler gear

11 Volvo Trucks North America, Inc. Date Group No. Page TSI (11) 34 Install the cam sensor wheel on the camshaft drive gear. Install and torque-tighten the three bolts to 25 Nm (19 ft-lb). 25 Nm (19 ft-lb) 35 Install the vibration damper and torque-tighten bolts to 50 ± 5 Nm (37 ± 4 ft-lb). 50 ± 5 Nm (37 ± 4 ft-lb) Note: New bolts should be used.

TSI Date Group No. Supp. Page

Volvo Trucks North America, Inc. Greensboro, NC USA Timing Gear Cover TSI Date Group No. Supp. Page 11.2001 215 006 1(7) Timing Gear Cover D12C Fig. 1: VOLVO D12C Engine W2003244 This information covers